One-piece hollow block with double thickness connecting ears



Feb. 13, 1968 w. E. CROWDER ONE PIECE HOLLOW BLOCK WITH DOUBLE THICKNESSCONNECTING EARS 5 Sheets-Sheet 1 Filed Jan. 4, 1965 I NVENTOR. WILL/AMf. Cpawpm Arm/mar Feb. 13, 1968 w. E. CROWDER 3,368,316

ONE PIECE HOLLOW BLOCK WITH DOUBLE THICKNESS CONNECTING EARS Filed Jan.4, 1965 v 5 Sheets-Sheet 2 1 r I I //0 /06 0 6 INVENTOR. W/L LIAM 25.020mm BYj Feb. 13, 1968 w. E. CROWDER ONE PIECE HOLL OW BLOCK WITHDOUBLE THICKNESS CONNECTING EARS 5 Sheets-Sheet Filed Jan. 4, 1965INVENTOR. WILL/AM f. Clean/05R HTT ENEY United States Patent 3,368,316ONE-PIECE HOLLOW BLOCK WITH DOUBLE THICKNESS CONNECTING EARS William E.Crowder, RD. 1, Mount Wolf, Pa. Filed Jan. 4, 1965, Ser. No. 423,134 3Claims. (Cl. 52593) ABSTRACT OF THE DISCLOSURE Toy and decorativebuilding blocks stamped from cardboard-like material and provided withside and end walls foldably connected with a top panel, said wallshaving positioning and connecting ears integral therewith and within theplane of'said Walls and arranged to fit sungly into complementary slotsin said top panel adjacent the edges or centrally of said panel.

This invention pertains to toy and decorative building blocks andaccessories and, more particularly, to such building blocks andaccessories which are formed from blanks of sheet material, such ascardboard, and the like, and capable of being folded into hollow formsfor use in the building of toy buildings, decorative structures, such asused in show windows, and various other types of similar arrangements.Depending upon the size of the blocks, they may be used to constructminiature types of buildings, walls, etc, or larger sizes resemblingstructures built from conventional sizes of cement blocks and the like.

A number of different types of blocks and similar structures of variouskinds, shapes and sizes have been devised heretofore for purposes offorming a number of different types of structural configurations for useas toys and otherwise. Many of these comprise rectangular hollowobjects, similar to blocks, and are capable of being arranged into wallssimulating buildings and various other kinds of structures. Certain ofthese prior devices have included securing and positioning means on thevarious elements, even to the extent of forming projecting ears ortongues which are received in appropriate slots and similar openings inother elements of the same type.

One of the difiiculties of these prior elements has been the provisionof tongues which must be folded from the plane of the member to whichthey are connected and from which they project, whereby the inherentstiffness of the sheet material in the vicinity of the tongue,especially where it is connected onto the supporting element, isweakened initially, whereupon continued use serves only to furtherweaken the ear until, after only relatively limited use, the ear isseparated from the block or other element to which it initially wasconnected.

Another difficulty associated with prior devices of the type referred tohas been the positioning of connecting or securing ears and slots atlocations more or less centrally of certain faces of the blocks andsimilar elements to be connected, whereby the disposing of positioningears within the slots to receive the same on other blocks and the likehas been accompanied by difficu-lty in viewing the ears and slots toconnect the same.

Still another difficulty existing in prior devices of the type referredto has consisted of the complexity of the structures enabling foldableblanks made from sheet-like material to be folded into hollowconfigurations of various shapes and secured in said shapes, followed bydifiiculty in disassembling said folded structures to restore the sameto flat condition for storage and the like.

It is a principal object of the present invention to provide hollowbuilding blocks and appropriate accessories suitable for use as toys,for decorative purposes, and the like, and formed from sheet material toprovide a blank comprising various types of connected panels which, whenfolded into a hollow configuration, are provided with ears which projectfrom the edges of opposite sides of said blocks and the like, within theplanes thereof, perpendicularly to one face of such block and theopposite face of said block is provided with slots therein along theedges thereof for the reception of ears of other blocks when stackedthereon to secure the assembled blocks in desired position with theouter surfaces thereof flush with each other so as to permit theconstruction of walls and other building arrangements, said ears beingplanar with respect to the panels to which they are connected andthereby preserve the inherent stiffness of the sheet material tomaintain the ears in vertical relationship with respect to the face ofthe block from which they project.

Another object of the invention is to provide a construction in saidblocks by which the various panels quickly and readily may be moldedwith respect to each other and secured against unfolding by interlockingarrangements of certain of the panels and means connected thereto, saidmeans readily being disengageable to permit the restoration of the blockto flat, unfolded position for storage and the like.

Details of the foregoing objects and of the invention, as well as otherobjects thereof, are set forth in the following specification andillustrated in the accompanying drawings comprising a part thereof.

In the drawings:

FIG, 1 is a perspective view of an exemplary playhouse comprisingblocks, lintels, and roof panels connected together and embodyingprinciples of the present invention.

FIG. 2 is a plan view of an exemplary flat blank from which arectangular hollow block readily may be formed by folding certain of thepanels into a block configuration.

FIG. 3 is a perspective view of a block folded from the lank shown inFIG. 2, as seen from the underside of the block when the central panelthereof is disposed lowermost.

FIG. 4 is a blank embodying the principles of the invention but arrangedfor purposes of being folded to form a substantially cubical block.

FIG. 5 is a perspective view of the type of block formed from the blankshown in FIG. 4 and illustrated in the final operation of beingcompletely folded into such type of block.

FIG. 6 is a blank comprising a plurality of connected panels arranged tobe folded into a hollow arrangement resembling a triangular block.

FIG. 7 is a perspective view of a block substantially completely foldedinto a triangular configuration from the blank shown in FIG. 6.

FIG. 8 is a plan view of a blank from which a lintel is to be folded inaccordance with the principles of the present invention.

FIG. 9 is a fragmentary perspective view of one end of a lintel arrangedsubstantially in completely folded condition as formed from a blank ofthe type shown in FIG. 8.

FIG. 10 is a plan view of a blank from which a roof panel is folded.

FIG. 11 is a perspective inverted view of a roof panel folded from theblank shown in FIG. 10.

Referring to the drawings, and in accordance with the principles of thepresent invention, it is contemplated that various types of playstructures, such as pl-ayhouses, as well as decorative structures andarrangements, such as might be employed in display windows and the like,can be formed from a number of ditferent shapes of hollow blocks,lintels, and roof panels, of which a limited number of exemplaryillustrations are shown in certain figures of the drawings, especiallyFIGS. 1, 12 and 13. One of the principal hollow building elementsembodied in these structures is a rectangular block one of which isshown in detail in FIG. 3, the same being formed from the blank 12 shownin FIG. 2.

The blank 12 preferably is formed from cardboard of a suitable gauge,such as 50 points, or the like, which, if desired, may be ornamented,such as by having a mottled appearance or the like printed on onesurface thereof and thereby permitting the folded block 10 to resemble acement block or the like. Marbleized appearances and the like also arepossible, as desired. Further, any appropriate color may be applied tosaid decorated surface of the blank which will be apparent on theexterior of the block 10 when folded into block configuration.

The blank 12 comprises a central panel 14 to the opposite side edges ofwhich similar side panels 16 are foldably connected by suitable scoring,rouletting, or the like, along lines 18. Also, similar end panels arefoldably connected to the opposite ends of the central panel 14 byappropriate scored lines 22 or the like. The end panels 20, for example,may be substantially half the area of the central panel 14.

Foldably connected to the opposite ends of the side panels 16 are endflaps 24 which are separated by slits 26 from the end panels 20, but arefoldably connected to the opposite ends of the side panels 16 by scoredlines 28 or the like.

Foldably connected to the outer ends of each of the end panels 20 byadditional scored lines 30 are locking flaps 32 which are provided withsemicircular openings 34 that are stamped therefrom. Similarly, theedges of the end flaps 24 adjacent the slits 26 are each provided withsemicircular openings 36 but the opposite edges of the end flaps 24 areprovided with preferably semicircular ears 38 which are similar in shapeto the openings 34 and 36.

Also foldably connected to the longitudinal outer edges of the sidepanels 16 are elongated, narrow latching flaps 40 which have notches 42therein for purposes to be described, the flaps 40 being connected tothe side panels 16 by scored lines 44 or the like.

To assemble the blank 12 into a rectangular block of the type shown inFIG. 5, the end flaps 24 are first folded upwardly from the side panels16 and said side panels then are folded upwardly relative to centralpanel 14 to dispose the previously folded end flaps 24 into overlappingengagement with each other, which engagement brings the cars 38 intojuxtaposition immediately adjacent each other in overlappingarrangement, thereby providing ears of double thickness and inherentlyrigid by reason of being unbent with respect to the plane of the end offlaps 24. The end panels 20 then are bent upwardly to overlie theoverlapping end flaps 24, followed by folding the locking flaps 32inwardly to enable the opening 34 to pass over and, in efiect, receivetherethrough the upwardly projecting ears 38. Lastly, by folding thelatching flaps inwardly and downwardly into the hollow rectangular block10, notches 42 thereof will be brought into engagement with the sideedges of the locking flaps 30 and thus secure the entire block intofolded configuration without auxiliary means of any kind being required.

The ears 38, which are provided on the block 10, project from the sameface of the block, said face being opposite the central panel 14. Theseears are for the purpose of securing the block and positioning it withrespect to other blocks when a plurality of such blocks and otheraccessories to be described hereinafter are assembled into a certainbuilding configuration, such as the exemplary playhouse shown in FIG. 1or the wall shown in FIG. 12. Such securing and positioning of the blockwith respect to other blocks is achieved by providing preferably in thecentral panel 14 a plurality of slots 46, which are best shown in FIGS.2 and 3. It will be seen also from these figures that the ears 38preferably are positioned midway of the opposite sides 15 of the block10 and, correspondingly, the slots 46 adjacent the opposite ends of thecentral panel 14 also are positioned midway of said ends between thescored lines 18 and along the scored lines 22. The slots 46 preferablyare snugly complementary to the ears 38 so as to somewhat frictionallyreceive the same and thereby accurately position one block on top ofanother.

Each of the longitudinal sides of the central panel 14 also are providedwith a pair of longitudinally spaced slots 46, which extend along thescored lines 18. Preferably, the central panel 14 is twice as long as itis wide and said pairs of slots 46 along the scored lines 18 are sopositioned that when a similar block, for example, is disposedtransveresly over one-half of the central panel 14 of another block, oneof the slots 46 along the lines 18 will receive the ear 38 on one end ofthe second block, as when the blocks are used to form a cornerconstruction of a wall or building, for example. In addition to theslots 46, the central panel 14 also is provided with a central slot 48extending transversely across the central face 14 with respect to andmidway between the opposite scored lines 18. The slot 48 preferably istwice as wide as the slots 46 although of the same length, whereby theslot 48 may receive a pair of the tongues 38 simultaneously from a pairof additional blocks disposed in end abutting relationship with thetongues 38 coinciding for reception within the slot 48, as when forminga staggered block arrangement similar to the pattern of conventionallaid brick or blocks.

As in the laying of conventional cement blocks, bricks and the like,what might be termed half-length are provided in accordance with theprinciples of the present invention, an exemplary illustration of onetypical construction of the same being shown in FIGS. 4 and 5.Preferably, the completed block 50 is cubical, all four sides and oneend thereof being closed while the sixth side or face is open. Such ablock conveniently may be formed from a blank such as that shown in FIG.4 which comprises four similar side panels 52 and an end panel 54 which,in use, functions similarly to the central panel 14 of the rectangulartype block 10 shown in FIGS. 2 and 3. The side panels 52 are allfoldably connected together by scored or rouletted lines 56 and endpanel 54 similarly is foldably connected to one of the side panels 52 byanother similarly scored or rouletted line 58.

A connecting flap 60 is foldably connected by a suitable scored line tothe outer end of one of the outermost side panels 52, and a locking tab62 is foldably connected to the outer end of the other outermost sidepanel 52, as best shown in FIG. 4. Flap 60 is provided with a slot 64which is complementary to the tab 62 and receives the same when the fourside panels 52 are foldably disposed into a square configuration.Similar edges of the side panels 52 also are provided with connectingand positioning cars 66 which function similarly to the ears 38 of theembodiment of FIGS. 2 and 3 and are similar in size and shape to saidears. The ears 66 are received in complementary positioning slots suchas the slots 46 or 48 of the block 10.

After the four side panels 52 have been folded into squareconfiguration, one of the open ends of such configuration is closed bythe end panel 54, opposite sides of which are provided with foldablyconnected flaps 68 and the scored lines by which the flaps 68 areconnected thereto have elongated slots 70 formed therein intermediatelyof the ends of said lines, the central portion of each of the slots 70being wider to provide an auxiliary slot 72, the latter beingcomplementary to the crosssectional shape of the cars 66 of similarblocks or the ears 38 of the blocks 10, for example, of the precedingembodiment.

The ends of three of the connected side panels 52 opposite the ears 66thereon are provided with foldably connected flaps 74 and 76, the flaps'74 having slots 78 therein, which are similar to the slots 72 for thereception of positioning ears, while flap 76 has a slot 80 therein whichreceives a locking tab 82 on the end panel 54 when the end panel isfolded into operative position, as shown in FIG. 5. Incident to foldingthe blank shown in FIG. 4 into the position shown in FIG. 5, the flaps74 are inserted into the slots 70 which are complementary in length tosaid flaps, while the flap 76 preferably'is coextensive in length withthe side panel 52 to which it is connected, but said flap is overlain bythe end panel 54 when the folding of the blank is completed to comprisewhat may be termed a half-length block.

By means of a substantial number of the rectangular blocks and a limitednumber of the so-called halflength blocks 50, a reasonable number ofregular configurations of walls, buildings such as playhouses,decorative I i-dimensional panels for use in window dressing of showwindows and the like may be formed. To enhance the types of structuresand render greater versatility to a set of toy or decorative buildingblocks such as comprise the present invention, it is furthercontemplated that triangular blocks also be provided, an exemplary blankfrom which the same can be folded being shown in FIG. 6, while thenearly completely formed triangular block is shown in FIG. 7. Referringto these figures in detail, it will be seen that such triangular block84 has an outer diagonal panel 86 to opposed sides of which similartriangular panels 88 are foldably connected by scored lines 90 or thelike. Also foldably connected to one edge of one of the triangularpanels 88 is a so-called vertical panel 92 having a foldable end flap 94movably connected thereto and provided with a locking slot 96 whichreceives a locking tab 98.

By folding the triangular panels 88 perpendicularly with respect to thepanel 86, and then folding the vertical panel 92 perpendicularly to thetriangular panel 88 to which it is connected, the end flap 94 may bedisposed adjacent the inner surface of the other triangular panel 88 andlocking tab 98 is inserted into locking slot 96 to complete formation ofthe triangular block 84.

To secure the triangular block 84 to other building blocks of the set ofrelated blocks comprising the present invention, each of the free edgesof the panels 86, 88 and 92 are provided with locking or positioningears 100 which are similar to ears 38 and 66 of the above-describedblocks, such ears100 being for the same purpose as said other ears withrespect to blocks upon which the triangular blocks 84 are adapted to bemounted, such as for purposes of forming gable walls, for example, asshown in FIGS. 1 and 13, or for forming pinnacles or parapets, such asillustrated in FIG. 12.

In addition to the various formations of blocks illustrated in thedrawings and described above, a complete set of building elementsenvisioned by the present invention includes a lintel 102, the blankfrom which the same are formed being illustrated in FIG. 8, while afragmentary portion of a nearly completed lintel is illustrated in FIG.9. The blank shown in FIG. 8 comprises a central web 104 which, like theblock constructions described hereinabove, preferably is formed fromsuitable sheet material such as cardboard or the like of appropriatethickness. Foldably connected to opposite elongated edges of the centralweb 104 are relatively narrow side flanges 106 and spaced along thescored lines 108 which connect the same are a series of uniformly spacedear-receiving slots 110. The width of the central web 104 preferably isapproximately equal to that of the blocks 10, 50 and 84, for purposes tobe described.

Foldably connected to the outer edges of the side flanges 106 are pairsof interengageable ears 112 and 114. The ears of each pair aretransversely opposite each other and said pairs are spacedlongitudinally from each other as well as from the opposite ends of thecentral Web 104. Said ears preferably are connected to the flanges 106by scored lines and the ears 112 have slots 116 which receive thelocking tabs 118 on the ends of ears 114.

When the side flanges 106 are folded in the perpendicular relationshipto the central web 104 as shown in FIG. 8 and the ears 112 and 114 arebent toward each other so as to permit reception of the locking tabs 118within slots 116, it will be seen that the lintel 102 is a channellikearrangement which preferably is mounted with the central web 104uppermost and the open channel-like ends thereof respectively aredisposed on top of spaced blocks, such as shown in exemplary manner overthe doorway 120 or window opening 122 of the exemplary structure shownin FIG. 1. There is sufficient space at the ends of the lintel 102 whichis unobstructed by the ears 112 and 114 to amply permit such use of thelintels.

To facilitate the cooperation of the lintels with other blocks bothabove and below the same, the central web 104 is provided along thescored lines 108 with the earreceiving slots 110 and preferablyextending transversely between the lines 108 is a central transversedouble-width slot 124. Also, semicircular ears 126 are partially cutfrom the material of the blank and are foldably connected to the centralweb 104 so as to be bent into perpendicular relationship relativethereto, as shown in FIG. 9, for reception in positioning slots inblocks below the lintel, while positioning ears on the lower face ofother blocks placed above the lintel are received in the slots 110 and124, thereby accurately positioning the lintel with respect to adjacentblocks associated therewith.

To complete the contemplated accessories referred to above, the presentinvention also contemplates a roof panel 128 which preferably isrectangular in shape and is formed from a blank cut from sheet materialsimilar to that from which the blocks and lintels described above areformed. The blank comprising the roof panel 128 is shown in FIG. 10 andincludes a central panel which preferably has a width substantiallyequal to the length of the rectangular blocks 10 so as conveniently toadapt the roof panels to building structures of the exemplary type shownin FIG. 1. Foldably connected to the opposite longitudinal edges of thecentral panel 130 are narrow strips 132, each of which have similarlyspaced holes 134 therein capable of receiving fastening means such assplit rivets or the like and thereby affording ready means to secure aseries of said roof panels together in side-by-side relationship whenthe strips 132 are folded into vertical position relative to the centralpanel 130, as shown in FIG. 11.

Particularly for purposes of connecting the roof panels 128 to the upperportion of a simulated building struc ture, for example, one end of eachroof panel is provided with a series of foldably connected narrow strips136, 138 and 140 of uniform length which is equal to the width ofcentral panel 130. The ends of the connected narrow strips 136, 138 and140 are severed from end tabs 142 which are of the same width as strips132 and are foldably connected thereto.

The means by which one end of each roof panel is connected to a wallstructure, for example, of a simulated building comprises positioningears 144, which are integral with and preferably within the same planeas the endmost narrow strip 140, said ears actually being cut from theintermediate narrow strip 138, as clearly shown in FIG. 10. Accordingly,when strip 140 is folded relative to intermediate strip 138, along thescored line 146, the ears will project out of the plane of strip 138.Also, to complete the formation of the roof panel 128 shown in FIG. 11the end tabs 142 are first folded into the channel formed by the foldingof the narrow strips 134 relative to central panel 130 and then, ineffect, the narrow strips 136, 138 and 140 are folded around saidinturned tabs 142 so as to produce a configuration such as illustratedin exemplary manner at the left-hand end of the roof panel 128 shown inFIG. 11, whereby the positioning ears 144 project substantiallyperpendicularly from the general plane of the roof panel for receptionin the slots 46 of blocks or '72 of blocks 50, or even of slots 110 inthe lintels 102, depending upon which members are uppermost in thestructure to which the roof panels are to be connected. The infolding ofthe end tabs 144 serves to aid in retaining the narrow strips 132perpendicular relative to the central panel 130 of the roof panels 128.The opposite ends of the roof panels are such as to abut each other and,when the side strips 132 are connected together in the manner describedabove, the roof such as illustrated in FIG. 1 is relatively stable.

From the foregoing, it will be seen that the various shapes and types ofexemplary blocks illustrated and described herein, together with thecooperating accessories such as the lintels and roof panels, whensupplied in appropriate numbers of each, permit the construction of manyforms of decorative arrangements which may be used for store displays inshow windows or otherwise, as well as in the construction of many typesof playhouses, forts, and the like, capable of providing many hours ofdelight as well as constructive experience for children. All of theelements of a set of such blocks and accessories readily are foldableinto operative, 3-dimensional items requiring no additional securing orattaching means with the exception of a few simple split rivets or thelike for connecting adjoining roof panels together. At the end of theuse of a given arrangement of such elements, they may be readily andquickly disconnected for additional use while maintained in operativecondition, or, if desired, the various elements may be quickly restoredto fiat condition and thus compactly stored in a suitable carton or boxuntil the time for the next use thereof arrives. All of the parts may besuitably decorated to present an esthetic appearance when assembled inoperative condition and, further, all of said parts may be formed simplyand inexpensively from readily available material.

While the invention has been described and illustrated in its severalpreferred embodiments, it should be understood that the invention is notto be limited to the precise details herein illustrated and describedsince the same may be carried out in other ways falling within the scopeof the invention as claimed.

I claim:

1. A hollow building block foldable from a blank of cardboard like sheetmaterial for use as a toy and decorative purposes and the like, saidblank comprising a central panel having opposed pairs of parallel edges,side panels of similar shape to each other respectively foldablyconnected to one pair of said opposed edges of said central panel, endpanels of similar shape to each other and of the same width as said sidepanels foldably connected to the other pair of said opposed edges ofsaid central panel, end flaps foldably connected to the opposite ends ofeach of said side panels and of similar shape to said end panels andoverlying the end panels when said side and end panels are foldedperpendicularly to said central panel from the same surface thereof andwhen said end flaps are folded to extend perpendicularly from saidcentral and side panels, similar ears projecting from correspondingouter edges of said end flaps when so folded and overlying each otherwithin the planes of said fiaps, and means to secure said block infolded and erected position, and means including locking flaps foldablyconnected to the outer ends of said end panels and having openingscomplementary in shape to said ears, whereby when said locking flaps arefolded over overlying pairs of said ears the latter are received throughsaid openings to maintain said block in folded condition with said earsprojecting perpendicularly from the face of said blocks which isopposite said central panel, said central panel having slots thereinadjacent opposite edges thereof of a size adapted to receive the earsprojecting from similar blocks when placed upon the central panel ofsaid first-mentioned block to permit the interlocking of such blocksagainst relative lateral movement parallel to said central panels.

2. The building block according to claim 1 in which said central panelis rectangular and said slots therein being adjacent the end edges andalong the side edges of said panel intermediately of the ends thereof.

3. The building block according ot claim 1 said securing means furtherincluding latching flaps foldabiy connected to and extending along theouter edges of said side panels and having notches therein engaging thelocking flaps of the end panels to hold the same in folded lockingposition.

References Cited UNITED STATES PATENTS 1,193,975 10/1916 Beardsley 46-19X 2,292,188 1/ 1919 Wheeler 46-24 2,112,474 3/1938 Warren 4621 1,604,39110/1926 Croy 4625 2,618,887 11/1952 Frankenstein 46-11 2,861,388 11/1958Favaretto 46-16 3,264,021 8/1966 Artman 52594 X 2,131,349 9/1938 Kreider46-24 2,425,729 8/ 1947 Sherbinn 46-25 2,556,323 6/ 1951 Feigelman 46212,751,705 6/1956 Joseph 4624 2,874,512 2/1959 Joseph et al. 46-25FOREIGN PATENTS 642,020 5/ 1928 France.

58,080 8/ 1946 Netherlands.

F. BARRY SHAY, Primary Examiner.

L. G. MANCENE, Examiner.

